Application Case | Installing AtonMLS2 Bottom Line Breakline Sensor on Pattern Machine

1、 Project Overview

This case focuses on the pain points of mass production of computerized pattern machines in automated sewing processing plants. The customer mainly engages in sewing and processing of automotive interiors, luggage accessories, and shoe materials. The workshop is equipped with multiple high-speed fully automatic pattern machines, with a conventional production speed of 2500-3000rpm, using the industry's common "one person, multiple machines" automated production mode.

The computerized pattern machine is a fully automatic trajectory sewing equipment with complex operation paths, high degree of automation, and long continuous operation time. The equipment itself does not have reliable bottom line monitoring function, and there are long-term problems such as bottom line breakage and failure to stop the machine in a timely manner after the shuttle core is used up in the workshop, resulting in batch empty seams, workpiece scrap, and high rework rates, which are the long-term production loss pain points of the factory. To address issues such as missed detections, false alarms, and tedious debugging, the customer has installed AtonMLS2 baseline wire breakage sensors in bulk for equipment upgrade and renovation.

2、 On site issues before renovation

Before the renovation, the original ordinary bottom line detection accessories in the workshop were unable to adapt to the high-speed production conditions of the pattern machine, and four core problems were exposed during the production process:

1. Serious high-speed wire breakage and missed detection: When the equipment is running at high speed, the bottom line is instantly broken and the shuttle core stops suddenly. Traditional sensors have insufficient response speed and cannot trigger shutdown in a timely manner. The equipment continues to run empty seams, causing the entire batch of fabrics to be scrapped and material loss to remain high.

2. The workshop conditions have significant interference and frequent false alarms: the rotary shuttle position has accumulated oil and cotton fluff for a long time, coupled with high-frequency mechanical vibration of the equipment, ordinary sensors are highly susceptible to environmental interference, resulting in frequent false alarms and shutdowns, interrupting normal production cycles and affecting production capacity stability.

3. Replacement and debugging are tedious, time-consuming, and labor-intensive: Factory orders have multiple styles and frequent material changes. After replacing shuttle cores, wires, and fabrics, traditional detectors must readjust sensitivity and calibrate parameters, increasing machine maintenance workload and slowing down replacement efficiency.

4. The limitations of manual supervision are significant: one person is responsible for monitoring multiple pattern machines, which makes it impossible to monitor the bottom line status of each machine in real time. Relying solely on manual inspection has low fault tolerance and uncontrollable production quality risks.

3、 Renovation plan: Install AtonMLS2 bottom line disconnection sensor

In response to the structural characteristics and production conditions of the pattern machine, this upgrade adopts AtonMLS2 intelligent bottom line breakage sensor, which is installed externally without damage, without the need to modify the mechanical structure and internal circuits of the equipment. The signal can be directly connected to the original factory's electrical control system to achieve automatic shutdown and sound and light alarm for breakage.

The core adaptation advantages of this renovation plan are:

1. Intelligent adaptive debugging free: equipped with triple adaptive algorithms for distance, light, and dust shielding, compatible with commonly used ordinary shuttle cores, porous shuttle cores, and alumina shuttle cores in the workshop, suitable for various types of wire such as cotton thread, polyester thread, and elastic thread. Replacing models, materials, and shuttle cores does not require manual tuning, and can operate stably upon power on.

2. Suitable for 3000rpm high-speed sewing: with millisecond level signal response, it can accurately capture the bottom line breakage and shuttle core stop signal during high-speed sewing, instantly stop the machine, control the number of empty stitches within 2 needles, and prevent large-scale scrap.

3. Industrial grade anti-interference performance: Targeted filtering of oil pollution obstruction, cotton wool coverage, mechanical vibration, light changes and other interferences, completely solving the problems of traditional sensor false alarms and random shutdowns, and adapting to 24-hour two shift production conditions in the workshop.

4. Strong universality and low threshold for modification: Supports normally open/normally closed dual signal output, compatible with mainstream pattern machine brands and models in the market. Both new and old equipment can be quickly retrofitted, with low landing costs and quick results.

4、 Actual test results after renovation

After the equipment upgrade was completed, after 60 days of uninterrupted mass production testing, covering multiple categories of orders for order replacement production, the on-site improvement effect was significant:

1. Thoroughly solve the problem of missed detections: all bottom line breakage and shuttle core depletion faults can be accurately identified, and immediate shutdown alarms can be triggered. The workshop achieves zero waste of empty seams in batches, greatly reducing the cost of fabric loss.

2. More stable equipment operation: no invalid false alarms, no unjustified shutdowns, continuous and stable production pace, and significantly improved equipment utilization rate.

3. Reduce debugging and operation costs: The entire process is free of debugging and frequent maintenance, without the need for machine maintenance to repeatedly calibrate parameters, greatly reducing the time and pressure of changing orders for debugging and operation.

4. Adapt to less manual production: The one person multi machine operation mode is more stable, without the need for manual monitoring of the shuttle core status, reducing labor management costs and production risks.

5、 Case Summary

The upgrade and renovation case of the pattern machine proves that the AtonMLS2 bottom line breakage sensor can perfectly adapt to the production conditions of high-speed automated pattern machines, effectively solving the four major problems of high-speed missed detection, false alarm of working conditions, tedious debugging, and high scrap rate commonly found in the industry. With the characteristics of no debugging, high anti-interference, high precision, and easy installation, it has become the preferred transformation solution for sewing factory pattern machines to reduce costs, increase efficiency, and upgrade quality.

Core keywords

AtonMLS2 bottom line disconnection sensor; Bottom line breakage detection of pattern machine; Solution for pattern machine leakage; Computer pattern machine upgrade case; Sewing equipment breakage detection renovation

Frequently Asked Questions (FAQ)

Q1: Is the TonmLS2 bottom line breakage sensor compatible with all brands of computer pattern machines?

A1: Compatible with the vast majority of mainstream computer pattern machine models on the market, the equipment supports dual signal output of normally open and normally closed, without the need to modify the main structure of the equipment. Both new and old pattern machines can be retrofitted without damage, making it highly versatile.

Q2: Do I need to readjust the parameters of the pattern machine after replacing the wire and shuttle core?

A2: No need. The device is equipped with a triple intelligent adaptive algorithm, which can automatically adapt to different specifications of shuttle cores, various sewing wires and fabric conditions. The entire process of changing styles, materials, and shuttle cores is free of calibration and parameter adjustment, and can be used stably after power on.

Q3: Will the equipment frequently report false alarms due to excessive oil stains and cotton fluff in the workshop?

A3: No. The product is specially optimized for harsh working conditions in the sewing workshop, and can automatically filter out interference signals such as oil stains, cotton wool coverage, mechanical vibration, and light fluctuations, effectively preventing false alarms and shutdowns. It is suitable for 24-hour two shift production operations.

Q4: Can the bottom line break be accurately detected under high-speed 3000rpm conditions?

A4: Sure. The equipment has millisecond level high-speed response capability, which can accurately capture bottom line breakage and shuttle core stop signals during high-speed operation of the pattern machine, instantly stop and alarm, control the number of empty sewing needles within 2 needles, and completely solve the problems of high-speed missed detection and batch waste.

Q5: Is installation complicated? Can ordinary mechanics complete it independently?

A5: Easy and convenient installation, using external non-destructive installation method, easy wiring, no need to modify the internal circuit and mechanical structure of the equipment, ordinary machine maintenance personnel can quickly and independently complete installation and debugging, and the landing threshold is extremely low.